1.

, read thoroughly and understand the production of processes of cement and write
detail notes.

Methods of Manufacturing Process of Cement.

At present Portland Cement is manufactured by two processes, Dry Process, and Wet
Process.

The main difference between these two methods of manufacturing of cement is that in
the dry process, calcareous and argillaceous raw materials are fed into the burning kilns
in a perfectly dry state.

..and, In the wet process, however, these materials are supplied into the kiln in the form
of an intimate mixture with water called SLURRY.

1. Dry Process of Manufacture of Cement.

Following are the main steps in this process of cement manufacturing:

i. Treatment Of Raw Materials.

ii. Burning of the Dry Mix.

iii. Grinding of the Clinker.

iv. Packaging and Storage.

You’ll know all the process below in details.

(i) Treatment of Raw Materials:

The raw materials (limestone and clay) are subjected to such processes as, crushing,
drying, grinding, proportioning, and blending or mixing before they are fed to the kilns
for calcination or burning process.

The crushing stage involves breaking the raw materials into small fragments that vary in
size between 6-14 mm. Machines called Crushers are used for this purpose.

The drying stage is typical of the Dry Process. Drying of crushed materials is essential
and is achieved by heating these materials (separately) at temperatures sufficiently high
to drive out uncombined water.

Heating is done in drying kilns which are generally of the rotary type.

The grinding of each material as obtained from the driers is done in two stages.
First, the preliminary grinding, in which the materials are reduced to a fineness of 50
mesh. Ball mills are generally used for preliminary grinding.

Second, the fine grinding, in which the size of the materials is reduced to 200 mesh.
This is done by grinding in Tube Mills.

Each raw material is thus reduced to a required degree of fineness and is stored
separately in suitable storage tanks called SILOS or bins where from it can be drawn
out conveniently in requisite quantities.

Proportioning and Blending: Predetermined proportions of finely dried and

ground raw materials are mixed together before they are fed into the kiln.

The different materials thus combined together are mixed very thoroughly either by
mechanical or by pneumatic methods.

In the pneumatic blending, materials from different storage silos are simultaneously
drawn off and fed into a single silo that now contains mixed material.

In the pneumatic method, dry, proportioned materials are pumped under passive into a
blending silo, where-from they are drawn in the mixed state.

The blended materials are now ready for feeding into the burning kilns. From this stage
onwards, there is practically no major difference between the dry and wet processes,
except in the design of the rotary kiln.
Flow Diagram of Cement Manufacturing Process by Wet Method

2. critcally identify the defference and similarities between the dry process and
wet process of the
the productiion of cement including enviromental issue production cast out puts ?.

Difference between Wet and Dry process of cement

Wet process
1. Mixing of Raw materials in wash mill with 35 to 50% water.
 2. Materials exiting the mill are called “slurry” and have flow-ability characteristics.
3. Size of the kiln needed for manufacturing of cement is bigger.
4. Raw material can be mixed easily, so a better homogeneous material can be obtained
5. Fuel consumption is high i.e., 350 kg of coal per tonne of cement produced.
6. Cost of production is high.
7. Capital cost (Cost of establishment) is comparatively less.

Dry process

1. Mixing of raw material in dry state in blenders.

2. The dry materials exiting the mill are called “kiln feed”.
3. Size of the kiln needed for manufacturing of cement is smaller.
4. Difficult to control mixing of Raw materials, so it is difficult to obtain a better homogeneous
material.
5. Fuel consumption is low i.e., 100 kg of coal per tonne of cement produced.
6. Cost of production is less.
7. Capital cost is high due to blenders.

Which one is better?

If we consider the quality and rate then wet process is better and if we consider fuel
consumption and time of process then dry process is better.
Difference between dry and wet process in table form:-

Wet process
Dry process
1. Mixing of raw material in dry state in blenders. 1. Mixing of Raw materials in wash mill with 35 to

2. The dry materials exiting the mill are called “kiln feed”. 2. Materials exiting the mill are called “slurry” and

3. Fuel consumption is low i.e., 100 kg of coal per tonne of cement produced 3. Fuel consumption is high i.e., 350 kg of coal per

4. Cost of production is less. 4. Cost of production is high

5. Capital cost is high due to blenders. 5. Capital cost (Cost of establishment) is comparati

6. Size of the kiln needed for manufacturing of cement is smaller. 6. Size of the kiln needed for manufacturing of cem

7. Difficult to control mixing of Raw materials, so it is difficult to obtain a better 7. Raw material can be mixed easily, so a better ho
homogeneous material. obtained

DESCRIPTION OF THE PROJECT ENVIRONMENT In order to assess the baseline environmental status in
the study area around the proposed project area, a primary and secondary data collection programme
has been undertaken during the period July-Aug 07. The environmental components studied include: ‰
Physical/ chemical components: Physiography, Geology, Geomorphology, Hydrometeorology,
Hydrogeology, Surface and Ground water resources, Climatology, Meteorology, Ambient Air Quality,
Noise Levels, and Soil quality. ‰ Land use, archeology and cultural heritage ‰ Biological environment:
Flora and Fauna ‰ Socio-economic components: Demography, education system, agricultural system
and livestock, transportation networks and other infrastructure like water supply, public services, health
status and medical facilities. 4.1 TOPOGRAPHY & DRAINAGE Topography of the project area and of the
surroundings consists of plains, mountains and valleys. The drainage of the project area is governed by
the catchments of Blue Nile River, particularly Mugher river, which is one of the tributaries of the Blue
Nile. Mugher river flows west of the proposed plant site in a deeply incised valley, which is at an
elevation about 800 m lower than the plant area. 4.2 CLIMATE The climate of the area is characterized
by two distinct seasonal weather patterns; the wet season extending from June to September,
contributing about 70% of the annual rainfall, and the dry season which covers the period from October
to May. The minimum and maximum temperature in the area vary from 9o C to 23.5o C. The average
relative humidity during the year is 62%. The mean annual rainfall in the area is about 1158 mm. ESIA
Summary: Greenfield Derba Cement Project: DMC, Ethiopia 5 4.3 HYDROLOGY A detailed hydro-
geological study has been carried out in the area. The groundwater recharge of the study area of 10 km
radius around the plant and mining sites is estimated at 25 mio m3 / year. The total existing abstraction
in the area is 5.1 mio m3 / year, which is only 20% of the available groundwater resources. The net
available ground water in the area is 19.9 mio m3 / year. Thus it is safe to extract water from the area to
meet DMC’s total water requirement of 0.73 mio m3 / year (∼2000 m3 / day). 4.4 WATER QUALITY
Surface water samples from three (3) rivers, three (3) springs and a river confluence and ground water
samples from six borewells in the area have been analysed for their physico-chemical properties. All
samples are within the stipulated WHO/ Ethiopian Standards. 4.5 AMBIENT AIR QUALITY The ambient air
quality has been monitored at site and at various locations within the study area during the period
August-September 2007. The average total particulate matter in the area varied from 42.5 –118.8 µg/
m3 , PM10 varied from 13.3-54.4 µg/ m3 , SOx varied from 19.5-24.4 µg/ m3 and NOx varied from 6.3 –
9.5 µg/ m3 at the monitoring stations located at Plant site, mines, Derba & Lilo villages. All values are
within the draft Ethiopian AAQ standards. 3. determine the cement demand of Ethiopia in current five
year of tranformetion plan.

3. determine the cement demand of Ethiopia in current five year of tranformetion plan.

Ethiopia’s challenging cement market: consumption stimulation

Ethiopia’s cement industry has enjoyed substantial growth in the past decade. However,
challenges linked to the government’s investment policy could erode these gains, as Shem Oirere
reports With nearly 16.5 million tonnes of cement capacity and 10% average growth in annual
consumption, Ethiopia is among the top cement producers in sub-Saharan Africa. Only Nigeria
and South Africa rival it.
Concrete Paving, Compaction & Testing / January 26, 2018
National Cement factory, Ethiopia
Ethiopia’s cement industry has enjoyed substantial growth in the past decade. However,
challenges linked to the government’s investment policy could erode these gains, as
Shem Oirere reports
With nearly 16.5 million tonnes of cement capacity and 10% average growth in annual
consumption, Ethiopia is among the top cement producers in sub-Saharan Africa. Only
Nigeria and South Africa rival it.

The country’s cement capacity and consumption has been driven mainly by the federal
government’s five-year Growth and Transformation Plan to help the country achieve an
11-15% annual economic growth between 2010-2015.

Ethiopia has enjoyed a cement consumption boom in the five years to 2015 as the
government invested heavily in infrastructure, transport and otherwise. Projects include
new railway links such as the 900km Addis Ababa-Djibouti; the 289km Mekelle-Hara-
Gebeya; the 229km Hara- Gebeya-Semera-Assayita; and the 278km Awash-
Kombolcha-Hara-Gebeya. 

Massive public investment has also been seen in the energy sector - construction of the
6000MW Great Ethiopian Renaissance Dam as well as the 1870MW Gilgel-Gibe III and
254MW Genale Dawa hydroelectric projects.

Additional infrastructure projects such as the completion of the Assayita-Mekele and

Awash-Woldia railway corridors and construction of six rail networks to link Ethiopia’s
five key transport corridors should further boost cement consumption.

More roads

Prime minister Hailemariam Desalegn aims to double the road network from the
120,000km in 2014/15 to 220,000km by 2019/20. The government plans to increase the
percentage of paved road as a percentage of all road infrastructure from 13% to 16% by
2019/20.

The World Bank is already financing Ethiopia’s US$380 million Road Sector

Development Programme and Fourth Adaptable Loan Program Loan Project with a
substantial amount going towards upgrading three key roads. Improvement to the
highway network is expected to consume a large amount of cement, mainly for
strengthening a road’s sub-base and base and in the manufacture of concrete for the
wearing course. Planned road improvements include upgrading from gravel surface to
asphalt the 181km Mekenajo-Dembi Dolo and 121km Weikite-Hosaina link roads, while
the 89km Ankobr-Awash Arba earth surface road will be raised to asphalt status.

More than 17 companies are competing in Ethiopia’s cement market. Dangote Cement’s

Dangote Industries Ethiopia is taking the lion’s share after the Nigerian-based company
commissioned a 2.5 million-tonne plant in 2015. The plant, 90km from Ethiopia’s capital Addis
Ababa, is the largest and most modern cement plant in Ethiopia, producing 32.5 and 42.5-grade
cements, according to the company’s latest annual report.
However, over half of the plants in Ethiopia use old technologies such as vertical kilns and they
rely on older quarries that are difficult and costly to mine. To stay ahead of the pack, Dangote
says it opted for modern cement making technologies. These include dry-process rotary kilns
with pre-calciners that boost a manufacturing plant’s performance levels but use less energy.

Other cement market players in Ethiopia are Mugher Cement, Derba Midroc, National Cement,
Abyssinia Cement, Jema Cement, Messebo Cement Factory, Ture Dire Dawa, East Cement,
Huang Shuan Cement, CH Clinker Manufacturing, Inchini Bedrock, Red Fox Cement,
Debresina, Habesha and Ethio Cement. Around 70% of the cement production market is
controlled by Derba Midroc, Mugher, Messebo, Habesha and Dangote. Dangote says that its
market share is 27%. The rest of the producers are small cement plants relying on vertical shift
kiln technology, according to a Ministry of Industry report, Cement Industry Development
Strategy 2015-2025.

The ministry says in the report that emerging evidence shows “production capacity has grown
more than demand leading to under-capacity production”. As a result, “some cement companies
have started to struggle for survival due to substantially low capacity utilisation compared to
global standards”.

Ethiopia’s cement production utilisation rate is estimated at 50% compared to the global
average of 60-70%.

Stimulation measures

Ethiopia has proposed a number of measures to stimulate cement consumption, such

as the introduction of a rural housing construction code that stipulates the use of a
minimum amount of cement. Ethiopia hopes to construct at least 3.4 million rural
housing units by the end of 2017, although the target looks unachievable for now.
Based on the proposed minimum cement use in rural housing construction, an
estimated 5 million tonnes of cement could be used up to 2021, according to the
Ministry of Industry.

In addition, the government has set out plans for concrete road construction targeting
high traffic volume roads, expressways and ring roads. With an estimated 3,400km of
planned asphalt roads for construction, including those in industrial parks, the Ministry
of Industry estimates that nearly 7.6 million tonnes of cement will be used by 2021.
Other stimulation measures include the use of concrete to manufacture products such
as poles and cement roof tiles.

Another option is to export cement, especially to Kenya, South Sudan and Djbouti.
However, the Ministry of Industry says this could be uneconomical because of
Ethiopia’s “underdeveloped infrastruct- volume nature of the cement itself”.

Apart from these government-led measures to encourage cement consumption, the

country’s huge public sector-led economic growth - averaging 10.8% since 2005 - is
expected to continue. Growth could be as much as 8.1% in 2016/17 and 2017/18,
according to the African Development Bank. This forecast is much higher than that for
Ethiopia’s East African neighbours. Among expected drivers of cement consumption
growth in Ethiopia are the emergence of a fast-growing middle class, rapid urbanisation
that requires improved roads and the need to plug urban and rural housing deficits.

More foreign companies and private firms are pushing for a share of Ethiopia’s cement market,
encouraged by the country’s abundance of raw material such as limestone, sandstone, clay,
gypsum and pumice. This is not to mention cheap electricity expected once the Great
Renaissance Dam is completed. In May, prime minister Desalegn opened a cement plant by
Habesha Cement, which is owned jointly by South Africa’s Industrial Development Corporation
and Pretoria Portland Cement. Commissioning of the plant increased Ethiopia’s annual cement
production capacity to 16.4 million tonnes - nearly 10 times more than a decade earlier, despite
the country’s cement per capita consumption remaining at a low 61kgs.

Dangote has also signed an agreement with Ethiopia to double its cement plant,
commissioned in 2015, with a second line by the end of this year or early 2018.

India-based Birla is also expected to make a final decision on its investment in a

planned cement plant in Ethiopia. The company, an affiliate of M.P. Birla Group, already
has exploration licenses for limestone and coal to power the proposed plant.

Despite planned new capacities by Dangote and other foreign firms, international
cement makers in Ethiopia are facing a new challenge. Regional governments - where
raw materials are mined - announced measures to increase the share of local content in
foreign-backed cement projects. For example, mining of the cement additive pumice is
regulated by regional governments, with little intervention from the federal government.
The administration of the East Shewa Zone within the Oromia Region has written to
foreign firms that mine pumice to suggest that they cede some of their operations to the
cooperatives of unemployed youths in their areas.

Dangote, which operates 11 cement plants in eight countries with a combined capacity
of 44 million tonnes, has opposed the move by the Ethiopian regional administrative
unit. It’s a “violation of our rights because the [federal] government has given us a
mining licence”.

Dangote Cement’s executive director Edwin Devakumar hit out at the proposal in June.
Dangote is said to have invested $700 million in its first phase of the planned Ethiopian
cement industry expansion program. “If I do not have limestone and additives, my
cement plant is useless,” he told local media.
 Despite the emerging challenges, Ethiopia’s public budget capital investment over the
next five years and its huge of population of 100 million people - growing at 2.3% - is
expected to create numerous opportunities for production and consumption of cement.

COMPANIES IN THIS ARTICLE

World Bank

Dangote

African Development Bank

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4. calculate the expected local cement production capacity and comment on
whether we will have enough cement supply from the local market at the end of
2020. ?
MIDROC HOLDING (Al-Muwakaba For Industrial Development and Overseas Commerce) is a large
company having many business interests in Ethiopia, Saudi Arabia and other countries. DERBA MIDROC
CEMENT PLC is proposing to establish a green field cement plant of capacity 5,600 tonnes per day (tpd)
of clinker (cement capacity of 7000 tpd) based on Derba limestone deposit in Ethiopia. This ESIA
Summary outlines the Summary of the Environmental and Social Impact Assessment (ESIA), the
Environmental and Social Management Plan (ESMP) and the Resettlement Action Plan (RAP) formulated
for the proposed project, which includes the cement plant, captive raw material mines, proposed roads
from the plant to the mines and from Derba village to the plant, belt conveyor from mines to plant,
water pipeline and the power transmission lines.

The cement plant is proposed to be located about 8 km from Derba village in Sululta Wereda in Shoa
Zone of Oromiya Regional State. The proposed mining area is located within the Aanda Weizero Peasant
Association in Sululta Wereda, Shoa Zone of Oromiya Regional State and is about 7 km (crow fly
distance) from the plant site. The Derba Cement plant site is about 70 km from Addis Ababa the capital
of Ethiopia. The coordinates and elevations of the plant and mining areas are given below. The project
location is shown in the map below. Coordinates : Latitude : 09 0 27’28” to 09 0 28’25”’N : Longitude :
38 0 34’31” to 38 0 35’23” E Elevation of Plant site : 2380 m to 2420 m above Mean Sea Level (MSL)
Elevation of Mining area : 1550 m to 1650 m above MSL Ordinary Portland Cement (OPC) and Portland
Pozzolana Cement (PPC) will be manufactured at the DMC Plant. Both the cements shall meet the
requirements of Ethiopian National Standard No. EN-197.

OPC shall be produced as per CEM-I - 42.5 grade and shall contain 95% clinker and 5% gypsum. PPC shall
be produced as per CEM-II - 32.5 grade and shall contain 67% clinker, 28% pumice and 5% gypsum. The
annual cement capacity of the plant shall be 2.46 million tonnes per annum. Cement consumption in
Ethiopia during the period 1997-2007 has grown well, with a Cumulative Annual Growth Rate (CAGR) of
around 10% per annum (pa). In the last 5 years, the growth rate was around 16.1% pa. The cement
consumption for the year 2006-07 is estimated to be around 2.05 million tonnes. The demand supply
gap for cement has been estimated as given below. Year Demand (million tonnes) Supply (million
tonnes) Gap (million tonnes) 2007 2.05 1.75 0.30 2008 2.66 2.01 0.65 2009 3.38 2.82 0.56 2010 4.19
3.50 0.69 The proposed plant capacity is primarily based on market considerations and the availability of
raw materials. The proposed location enjoys the twin advantage of proximity to raw material sources as
well as market offered by the Addis Ababa, which is the capital and largest city of Ethiopia. Addis Ababa
is also an important trade center of East Africa. DMC is expected to command a market share of around
37% in its 1st year of operation, which will increase to 41% in its 4th year of operation. The plant will
achieve 100% capacity utilization in its 4th year of operations. The raw material and fuel requirements
for the proposed plant are to be met from different sources as given below. Sn Material Source Locality
Distance from plant (km) Remarks Raw materials 1 Limestone & Marl Mugher 6.5 The crusher, located in
the mine, would be connected to the plant by a 7 km long belt conveyor. 2 Clay Mulu Seyo 18
Considered as a corrective. 3 Sand Mugher 15 Considered as a corrective. 4 Basalt Near Gimbichu 10
Considered as a corrective. 5 Gypsum Mugher 15 Considered as an additive 6 Pumice Dera Ararate/
Nazerat 125 Considered as an additive Fuel 1 HFO Middle East - 2 Imported coal South Africa - Transport
by sea up to Djibouti port, land transport 925 km The limestone deposit at present is accessible by about
12 km foot track from Derba Cement plant site which is situated at a distance of 70 km from Addis
Ababa. The deposit is surrounded by Mugher river and its tributaries. Due to the natural topography of
the area, the limestone deposit lies in the valley (1550-1650 m above MSL) whereas the flat area where
the plant is proposed to be located is at an altitude of 2380-2420 m above MSL. There is a sharp fall in
elevation of approximately 800 to 850 m between the plant and the mining areas.

REGULATORY FRAMEWORK OF FDRE

Ethiopia adopted its Constitution in 1995, which provides the basic and comprehensive principles and
guidelines for environmental protection, and management in the country. The FDRE consists of the
Federal State and Regional States. Proclamations 33/ 1992, 41/ 1993 and 4/ 1995 define the duties and
responsibilities of the Regional States which include planning, directing and developing social and
economic development programs as well as protection of natural resources. The Environment
Protection Authority (EPA) has established an Environmental Impact Assessment system for Ethiopia
including the preparation of Procedural and Sectoral Guidelines as a prerequisite for the approval of
new development activities and projects. The EIA Process as applicable to development projects is
detailed in the ‘Environmental Impact Assessment Procedural Guidelines Series 1’ of November 2003. As
per Schedule I of the Guidelines, both cement plants as well as mining projects have significant
environmental impacts, and, therefore, require a full EIA/ EA study. The Derba Cement plant will be
responsible for implementing environmental management plans at its facilities in coordination with the
Federal EPA and the Regional EPA for Oromiya Region. The environmental performance of the project
will be monitored on a regular basis through DMC’s own set up and through external/ third party audits.

Demography
The Plant and Mining sites are located close Asfawu kiidane and arertie villages within Asfawu kidane
and Merete Gebria Peasant Associations (PAs) respectively. The demographic details of the three PAs,
viz., Asfawu kiidane (Plant area), Merete Gebria ro (Mining area) and Mulugeta tasewu (the closest
habitation of Derba) are given below:
 s Population Number of Households Avg. Popula
n Male Female Total Male Femal Total Fam tion
e ily Density
Size (person
s/sq
km
1 Asfawu kiidane 804 872 1676 269 18 287 5.8 31.59
2 Merete Gebria 891 1611 2502 514 235 749 3.3 33.62
3 Mulugeta tasewu 1825 2065 3890 1161 107 1268 3.1 147.46
POTENTIAL IMPACTS & MITIGATION MEASURES

The Operation phase of the proposed cement plant mainly comprises of the following activities: ‰
Excavation of limestone from the captive mines ‰ Transportation of crushed limestone from mines to
plant site ‰ Transportation of other correctives/ additives to the plant site ‰ Preparation of raw meal by
adding correctives to limestone ‰ Clinkerisation of raw meal ‰ Cooling and heat recovery ‰ Blending &
grinding of clinker by adding additives ‰ Packing & Despatch The details of main activities and actions to
be undertaken and their impacts during operation phase of plant and mines are summarized below.
Similar summaries have been prepared for the construction stage

CONCLUSIONS
The proposed cement project will impact on the physical, natural and socio-economic environments at
Derba. The plant and mining operations will result in permanent changes in the land use of the area.
Agricultural and grazing land will be converted to industrial and mining. However, the soil quality of the
area will remain unchanged. Air emissions from the plant will be highly controlled and the installation of
state of the art pollution equipment will limit the dust and gaseous pollutants levels much below the
norms specified by the IFC to ensure a continued good air quality in the area. The proposed plant and
mines will not affect the hydrology of the region. The drainage pattern will not be affected and the
quality of the water will also not be affected by the mining operations. The vegetation in the mining area
may be disturbed, causing a loss of crops, fruit trees and natural vegetation. However, the flora and
fauna existing in the area are of common species. Mitigation measures including a rehabilitation and
management program and a green belt/ afforestation plan will reduce the overall ecological impacts and
in the long term improve the forest cover to the benefit of the fauna diversity. Employment resulting
from plant and mining operations and associated services and improved infrastructure and facilities in
the area will be the main socio-economic benefits for the affected community. The acquisition of land in
the plant and mining area and the access roads and the resettlement of people living in these areas are
the major negative impacts of the project. The implementation of the resettlement action plan will
mitigate these impacts in terms of compensation and improvement of livelihood of the affected families.

5. Do you have a confidence or concern on the cement quality produced in

Ethiopia ?
Yes , cementis the priem ingredeient used in the constraction industry.
It is impossible to envisage a modern life without cement. Cement is an extremely important
construction material used for
housing and infrastructure development and a key to economic growth. Cement demand is
directly associated to economic growth and
many growing economies are striving for rapid infrastructure development which
underlines the tremendous growth in cement
production (Shraddha and Siddiqui., 2014). The cement industry plays a major role in improving
living standard all over the world by
creating direct employment and providing multiple cascading economic benefits to associated
industries. Despite its popularity and
profitability, the cement industry faces many challenges due to environmental concerns and
sustainability issues (Shraddha and
Siddiqui., 2014).
Concrete is the most common construction material used in building industry. Cement is a basic
component of concrete used for
building and civil engineering construction. On average approximately 1 ton of concrete is
produced each year for every human being
in the world. Therefore, concrete (i.e. cement) is one of the World‟s most significant
manufactured materials